Manufacturing Design, Production, Automation, and Integration Part 17 pps

By addressing the three important aspects of manufacturing—namely, design, production processes, and automation—it presents the state of the art in manufacturing as well as a careful tre

Man u fa ctu rin a J

Design, Production, Automation,

and Integration

Beno Benhabib

University of Toronto Toronto, Ontario, Canada

Although great care has been taken to provide accurate and current information, neither the author(s) nor the publisher, nor anyone else associated with this publication, shall be liable for any loss, damage, or liability directly or indirectly caused or alleged to be caused by this book The material contained herein is not intended to provide specific advice or recommendations for any specific situation Trademark notice: Product or corporate names may be trademarks or registered trademarks and are used only for identification and explanation without intent to infringe

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ISBN: 0-8247-4273-7 This book is printed on acid-free paper

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Current printing (last digit):

10 9 8 7 6 5 4 3 2 1 PRINTED IN THE UNITED STATES OF AMERICA

MANUFACTURING ENGINEERING AND MATERIALS PROCESSING

A Series of Reference Books and Textbooks

EDITOR

loan Marinescu

University of Toledo Toledo Ohio

FOUNDING EDITOR

Geoffrey Boothroyd

Boothroyd Dewhursr, Inc

Wakefield, Rhode Island

1 Computers in Manufacturing, U Rembold, M Seth, and J S Weinstein

2 Cold Rolling of Steel, William L Roberts

3 Strengthening of Ceramics: Treatments, Tests, and Desigin Applications, Harry P Kirchner

4 Metal Forming: The Application of Limit Analysis, Betzalel Avit.zur

5 Improving Productivity by Classification, Coding, and Data E5ase Standard- ization: The Key to Maximizing CADICAM and Group Technology, William F

Uyde

6 Automatic Assembly, Geoffrey Boothroyd, Gorrado Poli, and Laurence E

Murch

7 Manufacturing Engineering Processes, Leo Alting

8 Modem Ceramic Engineering: Properties, Processing, and lJse in Design, David W Richerson

9 Interface Technology for Computer-Controlled ,Manufacturing Processes, Ulrich Rembold, Karl Armbruster, and Wolfgang Ulzmann

10 Hot Rolling of Steel, William L Roberts

11, Adhesives in Manufacturing, edited by Gerald L Schneberger

12 Understanding the Manufacturing Process: Key to Successful CAD/CAM Implementation, Joseph Harrington, Jr

13 Industrial Materials Science and Engineering, edited by Lawrence E Murr

14 Lubricants and Lubrication in Metalworking Operations, Elliot S Nachtman and Serope Kalpavian

15 Manufacturing Engineering: An Introduction to the Basic Funictions, John P

Tanner

16 Computer-Integrated Manufacturing Technology and Systems, Ulrich Rembold, Christian Blume, and Ruediger Dillman

17 Connections in Electronic Assemblies, Anthony J Bilotta

18 Automation for Press Feed Operations: Applications and Economics, Edward Walker

19 Nontraditional Manufacturing Processes, Gary F Benedict

20 Programmable Controllers for Factory Automation, David G Johnson

22 Manufacturing High Technology Handbook, edited by Donatas njunelis and Keith E McKee

23 Factory Information Systems: Design and Implementation for CIM Manage- ment and Control, John Gaylord

24 Flat Processing of Steel, William L Roberts

25 Soldering for Electronic Assemblies, Leo P Lambed

26 Flexible Manufacturing Systems in Practice: Applications, Design, and Simulation, Joseph Talavage and Roger G Hannam

27 Flexible Manufacturing Systems: Benefits for the Low Inventory Factory, John E Lenz

28 Fundamentals of Machining and Machine Tools: Second Edition, Geoffrey

Boothroyd and Winston A Knight

29 Computer-Automated Process Planning for World-Class Manufacturing, James Nolen

30 Steel-Rolling Technology: Theory and Practice, Vladimir B Ginzburg

31 Computer Integrated Electronics Manufacturing and Testing, Jack Arabian

32 In-Process Measurement and Control, Stephan D Murphy

33 Assembly Line Design: Methodology and Applications, We-Min Chow

34 Robot Technology and Applications, edited by Ulrich Rembold

35 Mechanical Deburring and Surface Finishing Technology, Alfred F Scheider

36 Manufacturing Engineering: An Introduction to the Basic Functions, Second Edition, Revised and Expanded, John P Tanner

37 Assembly Automation and Product Design, Geoffrey Boothroyd

38 Hybrid Assemblies and Multichip Modules, Fred W Kear

39 High-Quality Steel Rolling: Theory and Practice, Vladimir B Ginzburg

40 Manufacturing Engineering Processes: Second Edition, Revised and Ex- panded, Leo Alting

41 Metalworking Fluids, edited by Jerry P Byers

42 Coordinate Measuring Machines and Systems, edited by John A Bosch

43 Arc Welding Automation, Howard €3 Cary

44 Facilities Planning and Materials Handling: Methods and Requirements, Viay

S Sheth

45 Continuous Flow Manufacturing: Quality in Design and Processes, Pierre C Guerindon

46 Laser Materials Processing, edited by Leonard Migliore

47 Re-Engineering the Manufacturing System: Applying the Theory of Con- straints, Robert E Stein

48 Handbook of Manufacturing Engineering, edited by Jack M Walker

49 Metal Cutting Theory and Practice, David A Stephenson and John S Agapiou

50 Manufacturing Process Design and Optimization, Robert F Rhyder

51 Statistical Process Control in Manufacturing Practice, Fred W Kear

52 Measurement of Geometric Tolerances in Manufacturing, James D Mea- dows

53 Machining of Ceramics and Composites, edited by Said Jahanrnir, M Ramulu, and Philip Koshy

54 Introduction to Manufacturing Processes and Materials, Robert C Creese

55 Computer-Aided Fixture Design, Yiming (Kevin) Rong and Yaoxiang (Stephens) Zhu

56 Understanding and Applying Machine Vision: Second Edition, Revised and Expanded, Nello Zuech

57 Flat Rolling Fundamentals, Vladimir 6 Ginzburg and Robert Ballas

58 Product Design for Manufacture and Assembly: Second Edition, Revised and Expanded, Geoffrey Boothroyd, Peter Dewhurst, and Winston Knight

59 Process Modeling in Composites Manufacturing, Suresh G Advani and E Murat Sozer

60 Integrated Product Design and Manufacturing Using Geometric Dimen- sioning and Tolerancing, Robert G Campbell and Edward S Roth

61 Handbook of Induction Heating, Valery Rudnev, Don Loveless, Raymond Cook, and Micah Black

62 Re-Engineering the Manufacturing System: Applying the Theory of Constraints, Second Edition, Revised and Expanded, Robert E Stein

63 Manufacturing: Design, Production, Automation, and Integration, Ben0 Benhabib

Additional Volumes in Preparation

This book is a comprehensive, integrated treatise on manufacturing engi-neering in the modern age By addressing the three important aspects of manufacturing—namely, design, production processes, and automation—it presents the state of the art in manufacturing as well as a careful treatment of the fundamentals All topics have been carefully selected for completeness, researched, and discussed as accurately as possible, with an emphasis on computer integration Design is discussed from concept development to the engineering analysis of the final product, with frequent reference to the var-ious processes of fabrication Numerous common fabrication processes (tra-ditional and modern) are subsequently detailed and contextualized in terms of product design and automation In the third part of the book, manufacturing control is discussed at the machine level as well as the system level (namely, material flow control in flexible manufacturing systems)

Although the book does discuss the totality of the design cycle, it does not present an exhaustive discussion of all manufacturing processes in exis-tence It emphasizes the most common types of metal processing, plastics processing, and powder processing, including modern processes such as laser cutting and numerous lithography-based methods In the third part of the book, continuous control is not discussed in detail; students interested in automation are expected to have a basic knowledge of the topic

Discrete-event control—a topic rarely introduced in manufacturing books—is ad-dressed because of its vital importance in system control

Although this book was written mainly for undergraduate and grad-uate students in mechanical and industrial engineering programs, its inte-grated treatment of the subject makes it a suitable reference for practicing engineers and other professionals interested in manufacturing For the classroom setting, the book offers the following benefits: (1) providing the undergraduate-level instructor with the flexibility to include several

advanc-ed topics in a course on manufacturing fundamentals and (2) providing graduate students with a background of manufacturing fundamentals, which they may not have fully studied as undergraduates

TEACHING MANUFACTURING ENGINEERING

USING THIS BOOK

Although manufacturing practice in industry has evolved significantly over the past two decades, existing textbooks rarely reflect these changes, thus severely restricting the way manufacturing courses are taught Most text-books are still compartmentalized in the manner that manufacturing practice was in the distant past; namely, there are design books, process books, and automation books In practice, manufacturing is a concurrent, integrated process that requires engineers to think simultaneously of all issues and their impact on one another This book attempts to advance the teaching of manufacturing engineering, keeping pace with practice in industry while providing instructors with options for course development Instructors can configure the book to be suitable for two consecutive (one-term) courses: one

at an introductory undergraduate level (Fundamentals of Manufacturing Engineering) and one at an advanced level (Manufacturing Automation): Fundamentals of Manufacturing Engineering

Chapter 1: Competitive Manufacturing

Chapter 2: Conceptual Design

Chapter 3: Design Methodologies

(Optional) Chapter 4: Computer-Aided Design

Chapter 6: Metal Casting, Powder Processing, and Plastics Molding Chapter 7: Metal Forming

Chapter 8: Machining

Chapter 9: Modern Manufacturing Techniques

Chapter 10: Assembly

(Optional) Chapter 11: Workholding—Fixtures and Jigs

Preface iv

(Optional) Chapter 12: Materials Handling

(Optional) Chapter 16: Control of Manufacturing Quality

Manufacturing Automation

Chapter 1: Competitive Manufacturing

(Optional) Chapter 2: Conceptual Design

(Optional) Chapter 3: Design Methodologies

Chapter 4: Computer-Aided Design

Chapter 5: Computer-Aided Engineering Analysis and Prototyping

(Optional) Chapter 9: Modern Manufacturing Techniques

(Optional) Chapter 10: Assembly

(Optional) Chapter 11: Workholding—Fixtures and Jigs

(Optional) Chapter 12: Materials Handling

Chapter 13: Instrumentation for Manufacturing Control

Chapter 14: Control of Production and Assembly Machines

Chapter 15: Supervisory Control of Manufacturing Systems

Chapter 16: Control of Manufacturing Quality

CHAPTER HIGHLIGHTS

Chapter 1 focuses on major historical developments in the manufacturing industry in the past two centuries The emergence of machine tools and industrial robots is discussed as prelude to a more in-depth review of the automotive manufacturing industry Technological advancements in this industry have significantly benefited other manufacturing industries over the past century Various manufacturing strategies adopted in different countries are reviewed as prelude to a discussion on the expected future of the manufacturing industry—namely, information technology–based manu-facturing

Chapter 2 emphasizes the first stage of the engineering design process: development of viable concepts Concurrent engineering (CE) is defined as a systematic approach to the integrated design of products and their manu-facturing and support processes Identification of customer need is described

as the first step in this process, followed by concept generation and selection The importance of industrial design (including human factors) in engineer-ing design is also highlighted The chapter concludes with a review of modular product design practices and the mass manufacturing of such cus-tomized products

Chapter 3 describes four primary design methodologies Although these methodologies have commonly been targeted for the post–conceptual

design phase, some can also be of significant benefit during the conceptual design phase of a product—for example, axiomatic design and group tech-nologyduring the conceptual design phase, design for manufacturing/assem-bly/environmentduring configuration and detailed design, and the Taguchi methodduring parametric design

Chapter 4begins with a review of geometric-modeling principles and then addresses several topics in computer-aided design (CAD), such as solid-modeling techniques, feature-based design, and product-data-exchange standards

In Chapter 5 a discussion of prototyping (physical versus virtual) serves as introduction to a thorough review of the most common computer-aided engineering (CAE) analysis tool used in mechanical engineering: finite-element modeling and analysis Subsequently, several optimization techniques are discussed

Chapter 6 describes three distinct fusion-based production processes for the net-shape fabrication of three primary engineering materials: casting for metals, powder processing for ceramics and high-melting-point metals and their alloys (e.g., cermets), and molding for plastics

Chapter 7describes several common metal-forming processes, focus-ing on two processes targeted for discrete-parts manufacturfocus-ing: forgfocus-ing and sheet-metal forming Quick die exchange, which is at the heart of pro-ductivity improvement through elimination of ‘‘waste,’’ is also briefly addressed

Chapter 8 surveys nonabrasive machining techniques (e.g., turning and milling) and discusses critical variables for finding material removal rate, such as cutting velocity and feed rate The economics of machining— which is based on the utilization of these variables in the derivation of the necessary optimization models—is also discussed in terms of the relation-ship of cutting-tool wear to machining-process parameters A discussion of representative abrasive-machining methods is also included

InChapter 9,several (nontraditional) processes for material removal are reviewed in separate sections devoted to non–based and laser-based fabrication This leads to a discussion of several modern material-additive techniques commonly used in the rapid fabrication of layered physical prototypes

Chapter 10describes various methods used for joining operations in the fabrication of multicomponent products These include mechanical fastening, adhesive bonding, welding, brazing, and soldering The chapter concludes with a detailed review of two specific assembly applications: au-tomatic assembly of electronic parts and auau-tomatic assembly of small me-chanical parts

Preface vi

In Chapter 11, following the description of general workholding principles and basic design guidelines for jigs and fixtures, the use of such devices in manufacturing is discussed, in the form of dedicated or modular configurations CAD techniques for fixture/jig development are briefly described

InChapter 12, the focus is on the handling of individual goods (i.e.,

‘‘unit loads’’) with a primary emphasis on material-handling equipment, as opposed to facility planning and movement control Industrial trucks (including automated guided vehicles), conveyors and industrial robots are reviewed as the primary mechanized/automated material-handling equipment The automated storage and retrieval of goods in high-density warehouses, as well as the important issue of automatic part identification (including bar codes), are also discussed The chapter ends with a discussion

of automobile assembly

Chapter 13 describes the various sensors that can be used for auto-matic control in manufacturing environments A brief introduction to the control of devices in the continuous-time domain precedes a discussion of pertinent manufacturing sensors: motion sensors, force sensors, and machine vision A brief discussion of actuators concludes the chapter

Chapter 14 focuses on the automatic control of two representative classes of production and assembly machines: material-removal machine tools and industrial robotic manipulators, respectively

Chapter 15describes two of the most successful discrete-event-system (DES) control theories developed by the academic community: Ramadge– Wonham automata theory and Petri nets theory The chapter ends with a description of programmable logic controllers (PLCs), which are used for the autonomous DES-based supervisory control of parts flow in flexible manufacturing workcells

Chapter 16 addresses quality control with an emphasis on on-line control (as opposed to postprocess sampling), focusing on measurement technologies and statistical process-control tools Inspection is defined and some common metrological techniques are presented An overview of probability and statistics theories are presented as prelude to a discussion

of statistical process capability and control A discussion of ISO 9000:2000 concludes the chapter

Beno Benhabib